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An operation and maintenance manual usually includes such items like starting
and shut down sequences, equipment maintenance, etc. However, what is often
missed is the communication of the design intent of the Engineer/Consultant,
to the operating personnel. There had been instances of improper plant
operation, because the operating personnel had not been made aware of how
the systems were designed to operate. This Manual has been prepared to
eliminate such deficiencies.
Further, Air Conditioning and refrigeration Engineering is a specialised linefrom the design stage to the ultimate service operations. It calls for detailed
application design, system and component selection, special care in
installation, commissioning and ultimately the day to day operation of the
Plant, its maintenance and trouble shooting. However well the plant has been
designed and installed, the full benefit of the Plant can only be obtained by
diligent operation and systematic maintenance.
In Central Air Conditioning systems-each Plant is tailor made to a great extent
to suit the job details and meet the maximum load conditions that can be
envisaged during the course of a year and also another special features that
may be required for a particular application. However, since the principle of
working, of the systems are practically same for the various applications, this
Operation and Maintenance Manual will be useful for all types of applications.
DESIGN DETAIL
Areas Air Conditioned
(i)
(ii)
(iii)
Sq. mtr.
Sq. mtr.
Sq. mtr.
Design conditions
Summer
DB WB RH
Winter
DB WB RH
Monsoon
DB WB RH
Outdoor
Indoor
Internal Load
No. of people
Lighting load
Equipment load
Refrigeration plants
Cooling coil
: Direct Expansion
type.
Chilled
water type
Condensing unit
: Water cooled.
Air cooled.
Chiller
: Direct Expansion
type
Type of Plant
PLANT DETAIL
EQUIPMENT
MAKE
TYPE/MODEL/
ENCLOSURE
HP/NOM.
CAPACITY
QTY.
Compressor
Compressor motor
Condenser
Chiller
Cooling tower
Cond. water pump
Chilled water pump
Cond. water pump motor
Chilled water pump motor
Cooling tower fan motor
Air Handling Units :
Size
Quantity
Motor HP
Filters - Qty
510 x 510 x 50
635 x 405 x 50
635 x 510 x 50
E lectrical Panel
Compressor
Condenser
Switch/Fuse
starter ra ting
O/L, U/V SPP
V/A meter S.S.
Evaporator
Fresh Air
Humidifica- Remark
tion
S.A. DIFFUSER
A.H.U. ROOM
PLANT ROOM
FRESH AIR DUCT
WITH DAMPER
FAN
SECTION
EVAPORATOR COIL
AIR FILTER
R.A. DIFFUSER
AIR-CONDITIONED ROOM
COND.
THERMOSTATIC
EXPANSION
VALVE
LIQUID LINE
STRAINER
COND. WATER
PUMP
DX SYSTEM
(a)
(b)
Operating Controls :
These vary according to the requirement of each job. In large size
plants (say at capacities of 40 tones and above) the compressors are
provided with capacity control to unload cylinder when the load drops
down. These are automatic devices which load and unload the
cylinders according to load variations. Provision of the capacity
controls also helps in unloaded starting of the plant, thereby reducing
the heavy draw of current of the compressor motor at the time of
starting.
CRANK CASE ELECTRIC HEATERS :
These heaters are provided in the Crank Case of the compressor to
keep the oil warm when the compressor is idle. The special
refrigeration oil used in the Compressors have a tendency to absorb
refrigerant gas when oil temperature falls down. Absorption of
refrigerant gas dilutes the oil and the lubricating property of the oil will
be substantially reduced; this will affect the bearing life of the
compressor. The crank case heater warm up the oil and reduces the
absorption of refrigerant gas during the idle period of the compressor.
The heater is connected in such a way that it comes ON automatically
as soon as the compressor is stopped/stops.
EVAPORATO
R COIL
AIR FILTER
AIR-CONDITIONED ROOM
EVAPORATOR COIL
AIR FILTER
AIR-CONDITIONED ROOM
EVAPORATO
R COIL
AIR FILTER
AIR-CONDITIONED ROOM
EVAPORATO
R COIL
AIR FILTER
AIR-CONDITIONED ROOM
DRAIN
PLANT ROOM
EVAPORATO
R COIL
AIR FILTER
AIR-CONDITIONED ROOM
COND.
COND. WATER
PUMP
COMPRESSOR OIL :
The refrigeration oil used in compressors is a speciality item, to
withstand the changes in temperature conditions in the system.
The Air Conditioning Plant being a heat exchange equipment, its
efficiency and the capacity it can deliver naturally will depend upon the
efficiency of the heat exchanging components, i.e., the evaporator and
condenser and also the efficiency of the compressor which maintains
the required flow rate and pressure for condensation of the refrigerant.
In the case of water cooled plants, since this heat is ultimately rejected
to the atmosphere through the cooling tower (again a heat exchanger)
the performance of the complete plant will be linked with the
efficiency of the cooling tower and the condenser water circulation
system.
Therefore, to get the maximum output of the plant, the various
components mentioned above have to be kept in good condition and
thus maintenance plays a very important role. Maintenance is detailed
in the subsequent chapters.
This chapter deals with the day to day operation of the plant. Operation of the
plant is not just starting and stopping the plant, but also includes some routine
maintenance work- on a day to day weekly and short period basis.
The result of faulty operation (including the routine maintenance) may escape
the attention, because it is not as dramatic as a breakdown, but in the long run
can work out to be quite costly. Therefore, proper operation is an important
aspect.
There may be symptoms of some minor malfunction, which may appear to be
small or insignificant; yet such small things can grow into major troubles in
course of time; resulting in costly and time-consuming repairs, loss of time,
dislocation and lots of extra work, usually at a most inconvenient time. So the
operating personnel should be sharp in detecting any minor defects and should
take timely action to prevent such minor defects grow into serious problems.
In an air conditioning plant, pressure, temperature, current etc. can never be
constant. These readings vary according to such factors as outside conditions,
room load, etc. The readings can vary during the course of a day itself.
Quite often it is assumed that as long as the temperature in the conditioned
area is within design limits, there is nothing wrong with the plant. But this is a
wrong assumption, because even a slightly inefficient plant can give
satisfactory inside-conditions if the load is less or outside-conditions are
comparatively low. It is the reading of the various temperatures and pressures
of the plant which can lead us to a positive conclusion about the conditions of
the plant. Therefore, one of the important aspects of operation is the logging of
the various readings (log sheet formats are given at the end of this chapter).
Needless to point out that readings should be taken correctly and the operating
personnel should have the ability to analyse the readings to establish whether
the plant is working satisfactorily or not.
OPERATING INSTRUCTIONS :
Before starting the Plant :
1.
2.
Refrigeration Systems,
(b)
(c)
3.
10
Check up water level in the cooling tower and ensure that the make up
water system is working satisfactorily-such as float ball is OK and float
valve is free in movement and there is water flow when the ball is
pressed down, etc., and there is regular make up water supply to
cooling tower.
During operation, some water is lost by way of evaporation and drift
losses. Unless these losses are made up continuously, the water level in
the cooling tower will fall down and the condenser will not get full and
continuous water flow thus affecting the plant; the discharge pressure
will shoot up and the plant will stop on High Pressure cut out switch.
4.
In chilled water plants, check the water level in the expansion tank and
ensure that the make up water system is working and there is regular
water supply.
Water level in the chilled water system can fall down due to pump
gland drips. If the level in the expansion tank is not maintained, air can
enter the chilled water system affecting the system performance
substantially and can even lead to freeze up of the chiller.
5.
Check all air filters and water strainers and clean whenever found dirty.
6.
Ensure that all doors and windows of the air conditioned area are
closed.
7.
Ensure that the crank Case of the Compressor is warm to the physical
touch. If it is not warm, check for defects in the Crank Case
heater/circuit. Do not start the compressor until the defect is rectified
and the Crank Case warms up. Otherwise, poor lubrication will result,
reducing the life of the bearings of the Compressor substantially.
8.
STARTING SEQUENCE
1.
2.
2.1
2.2
Start
Air handling unit motors
Condenser water pump/s. Check
that sufficient water pressure is
built up.
IMPORTANCE/SIGNIFICANCE OF
OPERATIONAL STEPS
Observe the voltage. If it is less than 380
volts, DO NOT START the plant.
11
2.4
2.5
2.6
2.7
3.1
load up.
12
3.2
13
14
15
Refrigerant
R-22
saturation
temperature - pressure chart is given
at the end of this chapter.
As the plant is started, the room
temperature will gradually fall down
and so also the suction pressure.
(f) Oil pressure : It is the NET OIL
PRESSURE developed by the oil
pump that is important. The net oil
pressure should be 2.8 kg/cm2 (40
PSI) more than the suction pressure.
(g) The pressure developed by the
condenser and chilled water pumps,
as already explained earlier, will
depend on the length of the water
circuits etc., and since these pressures
cannot change for a particular
system, the pressures observed at the
time of handing over should be the
best guide.
5.
6.
Check
for
any
unusual
noise/vibration in the plant. If
any is noticed, trace out the
reason for this and rectify. If
you are not able to identify the
cause of any vibration/noise,
contact maintenance. Agency /
manufacturer immediately.
7.
STOPPING SEQUENCE
1.
2.1
2.2
3.
4.
5.
16
Where standby plant/s, pump/s etc. are provided systematically change over
the work of the plants periodically say once in a week or even every day. This
will ensure uniform wear and tear of the plants. Further this also helps in
17
ensuring that all the plants are in good repair and the standby is in good
condition should a necessity occur.
2.
Never SWITCH OFF the main switch on the main electrical board or switch
off any component of the system, when the plant is in operation, for ease in
shutting down the plant. There had been instances of operators doing this way.
Such an action will put a heavy strain on the isolating switch/es and they can
even get completely damaged.
3.
All the water valves in the system can be kept open all the time and need not
be closed daily. But it is essential to close and open each valve periodically to
ensure that the valves work and do not get stuck by scale formation or dirt
accumulation.
4.
Keep the plant room clean. Do not use the plant room, particularly the air
handling unit rooms, as lumber rooms.
18
DATE :
TIME
CANVAS
DB WB
AHU-1
RETURN
DB WB RH
CANVAS
DB WB
AHU-2
RETURN
DB WB RH
Outside Temp
DB
WB
RH
Inside Temp
DB
WB
RH
Inside Temp
DB
WB
RH
Remarks
19
Out
Amps.
In
Out
In
Out
In
Out
In
Out
In
Out
In
Out
In
Out
In
In
Out
In
PRESS.
PRESS.
Amps.
COND-2
Out
Amps.
COND-1
Out
Amps.
In
COMP-1
S.P.
D.P.
O.P.
Amps.
TIME
Out
Amps.
In
DATE:
20
MAINTENANCE
DAY TO DAY MAINTENANCE :
It is a well known fact that all mechanical equipments need systematic
maintenance. In the case of Air-conditioning plant this aspect assumes greater
importance. Unless the work of maintenance is carried out in a planned
manner needless to point out that the full capacity of the plant not be obtained.
Further by proper maintenance work major-break down of the plant can be
substantially reduced.
It has been explained in the Chapter-3 that an Air-conditioning plant is a heat
exchange equipment. So to get the bast out of the plant, the heat exchangers
should be kept in good condition in addition to the maintenance work required
for any Electro-Mechanical equipment.
Maintenance pertaining to the Air-conditioning plant falls into two-categories.
1.
2.
2.
3.
21
5.
6.
LOG BOOK :
It may appear as a bit odd to talk about logging readings as a
maintenance step. But, remember that, it is the readings that tell the
real condition of the plant. If the readings show any abnormality, there
is some malfunctioning somewhere and this has to be investigated and
rectified without delay to avoid a major breakdown. This log book
forms an important maintenance tool for day to day operation of the
plant, as well as for future reference.
7.
WEEKLY :
1.
22
the coil. Hence, air filters are to be cleaned regularly. Weekly cleaning
has been suggested here. But where plants are installed in dusty
environments, it may be necessary to clean the air filters more often.
For example after a dust storm in Northern India, it is a must to clean
the air filters.
Air filters should be changed, when it is found that cleaning does not
remove all the dust.
2.
3.
4.
5.
23
Check the tension of belts and tighten whenever found loose. A loose
belt will reduce transmission efficiency and its own life will be
reduced; further the drive pulleys can get heated up. Replace belt when
it is not possible to tighten them any further. In mullet-belt drives,
change the complete set of belts. Select the belts for a matched set. If
this is not done, the load will be taken only by the smaller length belts,
thereby affecting transmission efficiency and belt life.
6.
7.
8.
Drain, clean and refill the cooling tower sump. Cooling towers, being
in the open, collect lot of dust and muck, hence it is necessary to clean
once in a week.
Analyse the pressure and temperature readings of the plant from the log
book and establish that the plant is working satisfactorily. Corrective
action should be taken promptly when readings show even a minor
malfunction
PREVENTIVE MAINTENANCE :
As the name implies, Preventive Maintenance is a planned service programme.
This helps in minimizing major breakdown, to operate the plant at design
efficiency and also to save energy. As explained in Chapter 5, this
maintenance work calls for the services of a well experienced
Serviceman/Service Engineer.
A step by step procedure in this regard in given below as a guideline :MAINTENANCE
FREQUENCY
1.
1.1
1.2
1.3
1.4
(once
in
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
2.
2.1
CONDENSER :
24
25
COOLING COIL :
The temperature difference between the canvas Half yearly or oftener.
connection
temperature
and
evaporator
temperature is the criterion to determine
whether the coil needs cleaning. The
temperature difference found at the time of
commissioning and handing over the plant is the
best guide. Cooling coils also are to be cleaned
with water under pressure.
3.
4.
Half yearly.
Note : Do not dress the Contacts with emery or sand paper. The contacts have hard
wearing coatings. If emery or abrasive paper is used, this coatings may get
removed. The shape of the contact point surfaces are made slightly sloping so
that the moving contact surface slides on the surface of the fixed contact and
maintains a positive contact. Thus the initial points of contact where arcing
occurs on making and breaking (which causes the pitting of the contact
26
surfaces) are not the areas through which current passes in operation. These
specially shaped surfaces can get out of proper shape if emery paper is used.
Therefore cleaning should be done only with cloth. Replace badly pitted
contacts.
27
TROUBLE SHOOTING
Even with a well maintained and operated plant troubles can develop. When
trouble occurs, a systematic study of all symptoms (by taking temperature and
pressure readings) should be made to come to a conclusion as to the cause of
the trouble.
Many of the breakdowns are caused originally by simple faults. Hence, while
trouble shooting, look for simple points first. Never jump to conclusion from
some symptoms only. Analyse all symptoms and come to a logical conclusion.
A properly maintained log book will help to a great extent to pin point the
probable area of trouble. Breakdown or major malfunctioning generally will
not occur all of a sudden. A small defect will develop into a major one, if not
detected and rectified in time. For example, a very minute gas leak over a
period of time can lead to lot of problems, such as, insufficient cooling, poor
oil return, excessive heating of compressor head etc. If only regular leak test
was taken and the minute leak detected and rectified, all the major troubles
cited could have been avoided.,
A trouble shooting chart is given on the next page as a guide line.
28
POSSIBLE CAUSES
Compressor
(a) Main switch open
refuses
to
start
REMEDIAL
MEASURES
Close switch.
Correct the
replace fuse.
fault
and
Repair or replace.
Reset thermostat.
2.
Plant
Vibrating
3.
Compressor
noisy
29
(a) Too high an oil level causing Correct the oil level.
liquid hammering
(b) Liquid flood back to the Check for reasons for
compressor
liquid flood back and
rectify.
(c) Excessive wear on bearing
4.
High
Discharge
Pressure
30
enough
Clean strainers.
Low
Discharge
Pressure
Overhaul pump.
Remove excess refrigerant
from the system.
6.
refrigerant
(b) Too much liquid being fed Adjust the expansion valve
through expansion valve.
(c) Compressor
unloaded
31
7.
Remove
the
cylinder
covers, inspect valve plates
and rings and renew if
necessary.
Clean or replace.
8.
Clean.
Check
mechanism.
unloading
Compressor
(a) Capacity control gone out of Adjust.
not unloading
adjustment.
(b) Cut-outs
for
capacity Reset the cut-outs
automatic control not set capacity control.
correctly.
9.
Compressor
not loading
Rectify or replace.
of
32
11.
Compressor
(a) Expansion valve in correctly
loading and
adjusted .
unloading
intervals too (b) Oil pressure erratic.
short
Low
pressure
Compressor
(a) Oil trapped in the system.
oil
level
going own.
(b) Piston rings
leaking.
13.
Compressor
working
continuously
loose
oil
by
to
Leak test
refrigerant.
Readjust.
and
charge
Compressor
Readjust differential.
Note : 1.
2.
3.
33
34
Close the liquid outlet valve on the condenser/receiver and start the
compressor. The compressor should be run until the suction pressure
gauge indicates a pressure of 2 psig. The compressor should then be
stopped and discharge/shut-off valve should be quickly closed.
2.
35
moisture may settle on the system and causes heavy damage when the plant is
started up.
When reassembling the system, it is advisable that the liquid side should be
closed up. Before completely sealing the system, crack the liquid outlet valve
to purge air from the system. Close the valve immediately and make the final
joint. However, where the system has been kept open for a long time, it is
necessary to evaluate the system before charging gas.
Test the system for leaks with Halide torch. If everything is satisfactory the
compressor may be started in the following way :1.
2.
3.
Open liquid outlet valve. This will build-up a pressure in the system
and cause the low pressure switch to function and start the compressor.
(Note : If the low pressure switch contacts were kept mechanically
closed during pump down cycle, this must be removed. Also, if the
liquid solenoid valve was manually opened, it should be reset for
automatic operation).
4.
Check oil level in the crank case and the refrigerant charge. If
necessary, add oil and gas. In case of refrigerant shortage, bubbles may
appear on the liquid indicator in the refrigerant liquids line.
REFRIGERANT CHARGING :
If the system has lost refrigerant gas due to leaks, broken connections, etc., this
gas must be replaced in order to ensure proper operation. It is important that no
gas be added until all leaks have been repaired. Shortage of refrigerant may be
indicated by any of the following symptoms :1.
2.
Low suction pressure and low condensing pressure. This condition may
cause short cycling of the system.
3.
4.
Presence of the oil at leaking joint, connection, bolt and head etc.
To add refrigerant to the system, follow the procedure outlined below :1.
Back seat the compressor suction shut-off valve. Remove the plug
from the gauge port.
36
2.
Connect the charging line from the refrigerant drum to the gauge port
but before tightening the connections, ensure that all air is purged from
the line by cracking the outlet valve on the refrigerant drum.
3.
4.
Start the compressor. Crack the suction valve off the back seat and
open the refrigerant drum valve. Gas will start flowing into the system.
Charge the system slowly. Stop the charging every two or three
minutes. Allow the system to stabilize and check suction, pressure and
liquid indicator, etc. Repeat this process of charging until system is
fully charged.
5.
Watch the liquid level indicator and the suction pressure gauge. When
the bubbles disappear and the suction pressure is normal, close the
drum valve, back seat the compressor suction shut-off valve, remove
the charging line and plug the gauge port.
6.
2.
3.
System not properly evaluated after the system has been opened out for
repairs.
4.
Non-condensable gases will cause high condensing pressures This will reduce
the refrigeration capacity, increase the operating cost and cause erratic
operation of the system. It is necessary therefore that non-condensable gases
must be purged from the system as soon as their presence is evidenced. In
37
2.
3.
Slowly turn the valve system off the back seat from one to two turns.
Air will blow off if this is done slowly.
On central remote installations, a separate purge valve is generally
provided which is located at a highest point on the discharge line. On
such system this valve should be used for purging non-condensable
gases.